Sensor module, system, and method for sensors in proximity to circuit breakers

ABSTRACT

The present disclosure provides a method and system for mounting a current transformer in proximity to a circuit breaker of an electrical system. Generally, a plurality of current transformers (CTs) are provided to measure a plurality of branches from a main power supply and are accumulated on a sensor module. In at least one embodiment, the sensor module includes a molded polymer mounting support that can support the CTs. The polymer molded mounting support departs from the standard circuit board and is substantially less fragile. A wiring channel is provided within the sensor module so that CT output wiring can be safely routed to the output connector using as few as two soldered connections, rather than the typical six soldered connections required in existing branch monitoring systems. Multiple sensor modules can be stacked to allow continued alignment with the CTs and software/firmware/hardware can allow for any current polarity changes.

This application claims the benefit of U.S. Provisional PatentApplication No. 60/686,842 filed Jun. 2, 2005.

FIELD

This disclosure relates to electrical power systems. More specifically,the disclosure relates to methods for power distribution and electricalprotection for electrical power systems.

BACKGROUND

In many premium power applications and power distribution systems, it isdesirable to monitor individual branch circuit currents that distributepower from a main line to various circuit loads in an electrical system.An operator can be informed as to which connected loads are inoperation, whether connected equipment is idling or fully operating, andwhether any individual circuit is approaching overload and should beremedied.

In collecting data from many scattered circuit loads, currenttransducers (CTs) are often mounted in the system to gather current flowinformation. A typical mount is within the circuit breaker panelenclosure, where multiple branches from circuit breakers in the panelcan be conveniently monitored from a single location. Thus, a main powersupply enters the circuit breaker panel and the power is split intomultiple branches having circuit breakers protecting each branch. TheCTs are mounted electrically downstream of the circuit breakers in along circuit board placed adjacent the circuit breakers. In manyindustrial or data center applications, the connected loads are rarelyturned off to be serviced or repaired. Consequently, the reliability ofthe CTs with their respective board must be very high, since the CTs aretoroidal in nature and cannot be removed without disconnecting circuitwiring and interrupting critical power to loads.

In application, relatively thick wire is fed from the electrical loadinto the circuit breaker panel, through the appropriate CT for aparticular branch, and then into the contacts for the circuit breaker.However, there are several challenges. For example:

-   -   1. The standard 42-pole panel for circuit breakers has limited        space within its housing, typically resulting in the CT board        with the corresponding CTs being made long and thin and thereby        mechanically weak. Stability and integrity of the system is        compromised by the relative weakness of the CT board.    -   2. High voltage terminations at the individual circuit breaker        outputs are very close to exposed current sensor soldered        connections and thereby risk dangerous voltages entering the        low-voltage control circuit wiring and destroying aspects of the        electrical circuit and/or creating a safety hazard.    -   3. Typical CT boards require many extra soldered connections,        directly lowering reliability and performance due to lack of        mechanical strength.

Branch circuit monitors to date, such as those disclosed in U.S. Pat.No. 6,330,516 and U.S. Pat. No. 6,809,509, have been built on printedcircuit boards and thereby posses the disadvantages listed above. Thecircuit board is thin and tends to flex as thick branch circuit wirespass through the mounted CTs and can break the soldered connections,seriously impairing the performance of the branch circuit monitor.

For example, FIGS. 1A and 1B are schematic front and end views,respectively, of a prior art arrangement. A circuit breaker panel 2contains a circuit breaker assembly 4 having a plurality of circuitbreakers 6, 8. Conductive wires 10, 12 (relatively thick wires dependingon the power requirements) feed power from the circuit breakers to loads14, 16. A circuit board 20 having CTs 22, 24 mounted thereon is used tomeasure current of the wires 10, 12 passing through the CTs 22, 24between the circuit breakers and the loads. The CTs can eventuallyconnect to an output connector 18 starting with an output wire 26 fromthe CT coil wire that is soldered to a pin 28 at a soldered connection32. The CT with the pin is assembled to the circuit board 20 bygenerally extending the pin 28 through a hole in the circuit board andsoldering the pin to the circuit board at a soldered connection 34. Thesoldered connection 34 is in turn connected to a circuit board line (notshown) formed on the circuit board 20 that leads to another solderedconnection at the output connector 18. A ribbon cable (not shown) canconnect to the output connector 18 to carry output from the individualCTs to a monitoring system.

Each CT conductive path to the output connector has therefore threesoldered connections and each CT has two wires for a total of sixsoldered connections per CT. Generally, there are 21 CTs on a circuitboard for 21 circuit breakers, resulting in at least 126 solderedconnections per board. For the modem trend of a circuit breaker panelhaving 42 circuit breakers in line, there are 252 soldered connectionsfor such a typical circuit board branch monitoring system.

The bending stress 30 caused by pulling the thick wires 10, 12 throughthe CTs is concentrated on the CTs 22, 24 and its soldered connections,such as connection 28, resulting in damage to the unit and therefore thesystem, more frequently than is desirable. Also, connections on thecircuit board are exposed to dangerous voltages from the relativelyclose wires 10, 12.

Therefore, there remains a need for improvement in the method ofmounting and monitoring branch distribution power in such powerapplications and related systems.

SUMMARY

The present disclosure provides a method and system for mounting acurrent transformer in proximity to a circuit breaker of an electricalsystem. Generally, a plurality of current transformers (CTs) areprovided to measure a plurality of branches' power lines from a mainpower supply and are accumulated on a sensor module. In at least oneembodiment, the sensor module includes a molded polymer mounting supportthat can hold the CTs. The polymer molded mounting support departs fromthe standard circuit board and is substantially more rugged. A wiringchannel is provided within the sensor module so that CT output wiringcan be safely routed to the output connector using as few as twosoldered connections per CT, rather than the typical six solderedconnections per CT required in existing branch monitoring systems.Independent of the number of connections, the disclosure advantageouslyprovides a more rugged packaging and support arrangement than previouslyused. Multiple sensor modules can be stacked to allow continuedalignment with the CTs and software/firmware/hardware can allow for anycurrent polarity changes.

The disclosure provides a sensor module for wiring in an electricalsystem, comprising: a first portion of material with a second portion ofmaterial being disposed at an angle to the first portion; at least onepost coupled to the second portion, the post having an openingtherethrough oriented at an angle to the second portion; and at leastone current transformer coupled to the post, the current transformerhaving an aperture aligned with the post opening and the post adapted toinsulate the current transformer from a wire passing through the postopening.

The disclosure also provides a electrical system, comprising: anelectrical panel; a plurality of circuit breakers coupled to theelectrical panel at an incremental spacing relative to each other; and afirst sensor module, comprising: a first flange and a web coupled to thefirst flange and having a lesser cross sectional thickness than thefirst flange, the web having a plurality of openings formed therethroughat an angle to the web, and a plurality of current transformers coupledto the web of the molded portion, the current transformers aligned withat least a portion of the circuit breakers at the incremental spacing toallow wiring to pass through the current transformers in alignment withthe circuit breakers.

The disclosure further provides a sensor module for wiring in anelectrical system, comprising: a sensor support having a supportingsurface and a second surface at an angle to the supporting surface andestablishing a height above the supporting surface; at least one postlaterally coupled to the sensor support along the height of the secondsurface, the post having an opening therethrough oriented at an angle tothe second surface; and at least one current transformer coupled to thepost, the current transformer having an aperture aligned with the postopening and the post adapted to insulate the current transformer from awire passing through the post opening.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description, briefly summarized above, may be had byreference to the embodiments illustrated in the appended drawings,forming part of the present specification and described herein. It is tobe noted, however, that the appended drawings illustrate only someembodiments described herein and are therefore not to be consideredlimiting of the disclosure's scope, in that there can be other equallyeffective embodiments.

FIG. 1A is a schematic front view of an exemplary prior art electricalbranch monitoring system.

FIG. 1B is a schematic end view of the exemplary prior art electricalbranch monitoring system of FIG. 1A.

FIG. 2 is a schematic front view of an exemplary embodiment of anelectrical system having a monitoring system according to the presentdisclosure.

FIG. 3 is a perspective schematic view of one embodiment of a sensormodule as an exemplary sensor support.

FIG. 4 is a cross sectional schematic view of the sensor module of FIG.2 with a post and a current transformer coupled thereto.

FIG. 5 is a cross sectional schematic view of the sensor module of FIG.2 with a stepped post and a current transformer coupled thereto.

FIG. 6 is a perspective schematic view of interfaced sensor modulesbetween a plurality of circuit breakers and respectively electricalloads.

FIG. 7 is a perspective schematic view of one embodiment of a circuitboard as an exemplary sensor support.

DETAILED DESCRIPTION

FIG. 2 is a schematic front view of an exemplary prior art electricalbranch monitoring system. The electrical system 40 generally includes acircuit breaker panel 42 having an internal space that houses a circuitbreaker assembly 44 mounted thereto. The circuit breaker assembly 44includes one or more circuit breakers, such as circuit breakers 46, 48,58, 60, and 68. Generally, the circuit breakers are aligned inpre-established spaces on a circuit breaker assembly. It is customaryfor the electrical circuit breaker assembly to have 21 spaces forcircuit breakers in a vertical alignment. Sometimes the circuit breakerassembly has a similar arrangement to the side of an additional 21possible spaces for other circuit breakers. Recently, some circuitbreaker panels and associated circuit breaker assemblies have a verticalalignment of 42 circuit breakers for a more compact installation. Thecircuit breakers are generally numbered 1-21 or 1-42 on the panel tofacilitate ready identification for maintenance, monitoring, or otherfunctions. One or more electrical loads 54, 56, 98 are coupled to thecircuit breakers through one or more wires 50, 52, 88. The wires providepower to the electrical loads.

The diagram illustrates one exemplary main power supply 100 providingpower to the circuit breaker panel 42. It is known to those withordinary skill in the art that for different power requirements, such as240 volts, that two power feeds are required with one neutral, and for a3-phase power system, three power feeds are required with one neutral,and other arrangements. For multiple power feeds, multiple circuitbreakers can be coupled together for each circuit breaker connected toseparate power feeds for a given electrical load. Thus, the presentdisclosure contemplates such arrangements and is specifically includedwithin the scope of the disclosure and the claims that follow.

One or more sensor assemblies 61, 63, such as sensor modules to befurther described below, can be generally disposed between the circuitbreakers and the loads. Other sensor assemblies can include circuitboards, as modified herein, and other structures (herein “sensorsupports”) that can support one or more current transformers or othersensors attached thereto. Generally, the sensor assemblies 61, 63 willbe mounted inside the circuit breaker panel 42 for safety, security, andprotection of the sensor assemblies. The sensor assemblies can interfacewith each other in an interface area 66 described in more detail below.The sensor assemblies 61, 63 will generally include a plurality ofcircuit transformers (CTs), such as CTs 70, 72, 74, 78. In general, a CTis a wire wound toroidal coil on a conductive or nonconductive core.While it is envisioned that current transformers will be the principlesensor used on a sensor assembly, other types of sensors, such asvoltage, power and other sensors, are included, and thus the termcurrent transformer is used broadly to include such sensors. The CTs canhave an aperture formed within the CT through which a power wire, suchas wire 50, can be routed therethrough. The CTs can be specially coupledto the sensor assemblies as described below to reduce the bending stresscaused by the wires 50, 52, 88, passing through the apertures of therespective CTs. As described herein, at least one embodiment of thesensor assemblies 61, 63, such as the sensor modules 62, 64, avoids theprior art problems of relying upon the CTs to absorb the bending stress30, shown in FIGS. 1A, 1B.

Further, the sensor assemblies 61, 63 can include output connectors thatcan be coupled to a processor. For example, a first sensor assembly 61can include a first output connector 80. The connector can be amulti-pin connector, used in electronic connections, having as many as50 pins or more, to which the various wires from the sensors can beconnected. The connectors can be coupled to the sensor assembliesthrough the underside of the sensor assemblies so that a correspondingconnector can be inserted from a backside of the breaker panel. Theconnector 80 is shown schematically in FIG. 2 and is related to theposition of an output connector block 81 shown in FIG. 3 in oneembodiment. Alternatively, the connector 80 can be positioned on thefront of the sensor assembly, on an end, or at other orientations as maybe convenient. The first output connector 80 can be coupled to amonitoring system 91, having various components such as a processor 90,through a cable 84. In general, the output connector 80 will have outputterminals for each of the CTs on the sensor assembly. Thus, cable 84could be a ribbon cable, or other type of cable, such as an opticalfiber cable, capable of discriminating between the outputs of differentCTs. Similarly, a second sensor assembly 63 can likewise include anoutput connector 82 that can be electrically coupled to the monitoringsystem 91, such as the processor 90, through a cable 86. The processor90 can process the output from the CTs into various types of output,such as data, reports, or signals for further processing useful to themonitoring system and/or the operator. Furthermore, additionalprocessors, such as processor 92, can be coupled to the processor 90.The processors 90 and/or 92 can include a data memory storage 94 and canbe coupled to an output device 96, such as a display, printer,transmitter, or other devices that can provide output in differentformats.

In a similar fashion, the main power supply 100 can be coupled with amain circuit breaker 102. A main supply CT 104 can be coupled to themain power supply 100 to monitor aspects of the main power supply. Insome embodiments, a voltmeter 106 can be coupled to one or more of theelectrical conductors, such as the main power supply 100.

For some embodiments, where the circuit breaker assembly 44 includescircuit breakers 1-21, the first sensor assembly 61 can be used with itssimilar arrangement of 21 CTs. In other circuit breaker assemblies thathave a greater number of circuit breakers 1-42, a plurality of sensorassemblies can be used, such as the embodiment illustrated in FIG. 2.The sensor assemblies 61, 63 can be interchangeable in that they eachhave a similar profile and can interchange with each other. Each sensorassembly could include at least 21 CTs so that together they can servethe 42 circuit breakers. The present disclosure solves at least twochallenges in so doing. First, at least one of the sensor assemblies canbe inverted for the two interchangeable sensor assemblies to interface,i.e., rotated so that its bottom is the top and top is the bottom in anend-to-end fashion, such as illustrated in FIG. 2. Thus, the CTs onsensor assembly 61 would number 1-21 from the top of the sensor assemblyas viewed from the perspective to FIG. 2 to the bottom (i.e., from theoutput connector 82) while the inverted sensor assembly, such as sensorassembly 63, would number 21-1 from the top to the bottom, where the CTwould start near the output connectors on each sensor assembly.Software, firmware, and/or hardware coupled to the output of the CTswould have conflicting identities of two sets of 1-21 CTs, as well asone of the sets being in a reversed number sequence. Further, if theinverted CT is measuring current, the current flowing through the CTs ofthe sensor assembly 63 would be a reverse current (i.e., negative)compared to a normal flow of current (i.e., positive) flowing throughthe CTs of the sensor assembly 61. The present disclosure can use thenegative current advantageously using the software, firmware, and/orhardware the correct the CTs identities and to make adjustments for theinverted sensor support. Generally, when the monitoring system senses areversed current, such as through the CTs of the inverted sensorassembly 63, the system recognizes the negative current as an invertedsensor assembly and can remaps the identities of the CTs to correspondto the correct circuit breakers. In the illustration of FIG. 2, thefirst CT of the sensor assembly 63 would become CT 42 to correspondingto the circuit breaker 60. Similarly, the 21^(st) CT of the sensorassembly 63, that is CT 78, would be mapped to the 22^(nd) circuitbreaker, that is circuit breaker 68, and become the 22^(nd) CT to themonitoring system. Thus, CTs 21-1 would be re-identified as CTs 22-42,respectively, for the inverted sensor assembly to correspond with thecircuit breakers 22-42. The software, firmware, and/or hardware of thepresent disclosure can perform such re-identification automatically.

In a similar fashion, individual CTs can indicate a reversal of current,generally inadvertently. For example, a sensor assembly couldinadvertently have one or more CTs reversed during assembly and notdiscovered until the system is installed and operational. Likewise, oneor more of the CTs can fail and need a secondary CT coupled to therespective power wire. The secondary CT could be installedinappropriately and indicate a reversed current. Thus, in a similarmanner, the system can recognize the negative current as an inverted CTand translate the current as a positive current in conjunction with theother CTs associated with the sensor assembly or the system.

The second challenge solved by the present disclosure is in maintainingthe spacing between the CTs and corresponding circuit breakers in theinterface area 66. For example, the circuit breakers 58 and 68 aregenerally at fixed spacing intervals, dictated by the structure, therails, and other pre-assembled aspects of the circuit breaker assembly44. The close proximity of the spacing between the circuit breakers 58,68 has heretofore been problematic in abutting two prior art assembliessuch the circuit boards in the patents described in the Background. Theabutment would cause a misalignment between the respective CT and itscircuit breaker in the interface area, causing stress on the CT and theproblems described above.

The present disclosure also solves this difficulty by overlapping atleast one and generally two openings formed between the sensorassemblies and the respective circuit breaker(s). For example, thecircuit breaker 58 could be the 21^(st) circuit breaker in-the circuitbreaker assembly 44 and the circuit breaker 68 could be the 22^(nd)circuit breaker in the circuit breaker assembly 44. Thus, both circuitbreakers 58, 68 would be in proximity to the interface area 66 betweenthe two sensor assemblies 61, 63. The CT 74 having an aperture 76coupled to the second sensor assembly 63 can be aligned with thecorresponding opening 75 formed in the first sensor assembly 61 whereboth the aperture and the opening can align with circuit breaker 58.Similarly, the CT 78 (e.g., the 21^(st) CT of the second sensor assembly63) when inverted, could align with a corresponding opening 79 formed inthe first sensor assembly 61 and the 22^(nd) circuit breaker 68. Thealignment between the CTs and the interface includes one or more CTs inthe interface area that overlap with a corresponding opening in theadjacent sensor assembly and allows wires to pass in alignment betweenthe corresponding circuit breaker through the sensor assembly, and tothe load. For example, a wire 88 coupled to the circuit breaker 68 couldpass through the CT 78 and a corresponding opening 79 in the othersensor assembly and onto an electrical load 98. The CTs and openings canbe on one sensor assembly, or on both sensor assemblies in the 21^(st)position of each sensor support.

Further, the disclosure can provide for those instances where a CT for agiven wire fails to function. The present disclosure provides analternative to disassembling the system 40 and the particular sensorassembly with a defective CT. The disclosure can provide a secondary CTand exclude an output of a CT coupled to the sensor assembly thatotherwise would be used to monitor the conditions for that branchcircuit. The software, firmware, or hardware can detect when abnormalconditions exists by for example, comparing with stored historical dataor noting values lower or higher than predetermined values, and othermetrics. The system can trigger an alarm, make adjustments, or otherwisealert an operator. For example, a CT 160 coupled to a sensor assemblycould normally be used to monitor the conditions of branch wire 158. IfCT 160 fails, the processor 90 can provide an output indicating thecondition. A secondary CT 162 can be coupled for example by clamping theCT to the wire 158 without having to disconnect the wire 158. The CT 162can be independently coupled to the monitoring system, such as to theprocessor 90 or a connector for the sensor assembly. The monitoringsystem 91 can exclude the output, automatically or selectively, from thedefective CT 160 and use the output from the secondary CT 162 insubstitution thereof and independent of the CT 160.

FIG. 3 is a perspective schematic view of one embodiment of a sensormodule as an exemplary sensor assembly. The sensor assemblies 61, 63,described in FIG. 2, can comprise sensor modules 62, 64. In general, theterm “sensor module” herein will include a sensor assembly having arelatively significant height from a plane upon which it is mounted incontrast to a circuit board with a relatively insignificant height aboveits plane of mounting. The sensor module generally has a sufficientheight such that a wire from a circuit breaker can pass laterally (i.e.,sideways) through the sensor module in contrast to the wire passingabove it, as in prior efforts, measured from a plane on which the sensormodule is mounted. The sensor module can advantageously be moldedsubstantially as a unit or can be assembled from preformed sections.

The sensor module, such as the first sensor module 62, also shown inFIG. 2, is illustrated on its side to show the various portions thereofFor illustrative purposes and to provide a context to the figure, thewire 50, also shown in FIG. 2, is shown passing through the first CT 70,although certainly other orientations are possible. In general, thesensor module includes a first surface 108 that can provide a supportingsurface for the module on a structure to which it is coupled. A secondsurface 109 is formed at an angle to the first surface to establish aheight above the first surface for the sensor module. Advantageously,the height is of a dimension such that the wire 50 from a circuitbreaker (shown in FIG. 6) mounted adjacent the sensor module can passlaterally through the sensor module in alignment with the circuitbreaker, as described herein. Related structures such as a post with anopening, described below, can be laterally coupled to the second surfacealong its height and reduce or avoid the bending stresses from the wirepassing therethrough. This structure is in contrast to prior efforts,using for example circuit boards of relatively insignificant height,resulting in such bending stresses.

The module can include a first portion 110 that is sufficiently wide tomount to a structure, such as the circuit breaker panel 42, shown inFIG. 2. The first portion can establish the supporting surface 108. Oneor more mounts 130, in at least one embodiment, can extend outwardlyfrom the first portion of 110 as a tab with a mounting opening form andtherethrough to further allow coupling of the first portion 110 to thepanel 44. Other methods of mounting the sensor module such as retainers,adhesive, or other methods are contemplated. The sensor module 62further includes a second portion 114 disposed at an angle to the firstportion 110. The second portion can establish the second surface 109. Inat least one embodiment for commercial efficiency, the second portion114 can have a thinner cross-sectional area compared to the firstportion 110 in the same direction. For example, and without limitation,the first portion 110 can include a flange having a greater width thanheight and the second portion 114 could be a web having a greater heightthan width. The flange provides a quantity of bending stiffness to theweb across its smaller cross sectional dimension (i.e., thickness 166shown in FIG. 4) and the web provides a quantity of bending stiffness tothe flange across its smaller cross sectional dimension (i.e., thickness168 shown in FIG. 4) when the flange and web are coupled together. In atleast some embodiments, the sensor module 62 can further include a thirdportion 112. The third portion 112 can be similarly shaped as the firstportion 110 and can also be a flange, although other shapes arecontemplated. The sensor module further includes an output connectorblock 81 with an opening 81A, the block being coupled to the sensormodule 62 to allow an output connector 80, shown in FIG. 2, to beassembled thereto.

The sensor module can further include a recessed portion 116. In atleast one embodiment, the recessed portion 116 is adapted to allow anadjacent sensor module to be coupled thereto to form the interface area66. Thus, the recessed portion 116 is generally symmetrical with therecessed portion of an adjacent module. Further, the sensor modules canbe made interchangeable with each other, so that they can be invertedand still function in the intended manner as described herein.

The sensor module material can be any suitable material and if moldedwill be generally a polymer compound that can withstand some stresses.Advantageously, at least a portion of the sensor module isnonconductive. Exemplary materials for the sensor module are polymers,like polyesters, such as polyethylene terephthalate (“PET”), includingPET (FR530), and polybutylene terephthalate (“PBT”), including PBT(4130). PBT is especially preferred since it is highly temperatureresistant. Both materials are Underwriters Laboratories (UL) listedmaterials. Other structural materials, conductive and nonconductive canbe used.

One or more CT posts for supporting the CTs can be coupled to the sensormodule 62. In at least one embodiment, the posts are formed integrallytherewith during a molding process. The posts, such as 118, have anopening 150 formed to allow the wire, such as wire 50, to be insertedtherethrough. In general, the opening 150 will be aligned at an angle tothe second portion 114. When assembled, such as shown in FIG. 2, theopening 150 will be aligned with its respective circuit breaker to allowthe wire to be inserted through the opening and aligned with thecorresponding circuit breaker. Thus, the height of the opening 150 abovethe first portion 110 in general will correspond to the height of thecircuit breaker, such as circuit breaker 46, above the height of thepanel 42 when the sensor module 62 is mounted to the panel 42. In atleast one embodiment, the sensor module 62 can have 22 posts coupledthereto. The posts can allow for the customary 21 circuit breakers withthe 22^(nd) post to be used in conjunction with an adjacent sensormodule. More specifically, 21 posts in the sensor module 62 could haveCTs (shown in FIGS. 4, 5) mounted thereto. In the embodiment shown inFIG. 3, the CTs could be disposed on any post between post 70 to post126 for any correspond circuit breakers in the circuit breaker panel.Post 124 could be used to overlap with a CT mounted on a post of anadjacent sensor module (shown in FIG. 6) in the corresponding positionas post 126 is on the first sensor module 62. Thus, an overlapping post124 having an opening 125 has a general utility of allowing wire comingthrough a corresponding CT on an adjacent module through the opening 125that can continue to the corresponding electrical load, such as shown inFIG. 2.

The posts can generally be aligned at a consistent vertical height tocorrespond to the height of the circuit breakers. Further, the spacingbetween the posts, such as posts 118, 120, are generally at the samespacing as the circuit breakers in the circuit breaker panel to maintainan alignment with the wires passing therethrough to the circuitbreakers. The alignment helps reduce stresses on the wiring that in turnreduces stresses on the sensor module and circuit breakers. However, thegeneral diameter of a CT is larger than can be accommodated with therestricted spacing between the posts. Thus, the CTs can be assembled tothe sensor module in an alternating fashion as shown in FIGS. 4, 5described below. To assist in accommodating the alternating arrangement,a step 122 can be formed or otherwise coupled on one or more posts torestrict the axial (i.e. lateral relative to the second portion 114)movement of the CT along the length of the post. For example, post 120can be coupled with a step 122. Advantageously, the steps are includedon alternating posts to assist in appropriate placing of the CTs for theparticular post. In the interface area 66, the step can be provided bysurface 128 to restrict the axial movement of the CT along the axis ofthe post.

FIG. 4 is a cross sectional schematic view of the sensor module of FIG.3 with a post and a current transformer coupled thereto. The crosssection is shown through the post 118 of FIG. 3 and through a portion ofFIG. 6 with the addition of a CT and relevant wiring. The sensor module62 generally includes a first portion 110, such as a flange, a secondportion 114, such as a web, and in some embodiments, a third portion112, such as an additional flange. In general, the first portion 110 canprovide a mounting surface to some support structure, such as thecircuit breaker panel 42, shown in FIG. 2. One or more mounts 130 canfacilitate the mounting of the sensor panel 62 to a support structure.The shape of the sensor module 62 can vary significantly in size,height, orientation, relative widths, and thicknesses, and theillustration is only exemplary. In general, however, the sensor modulewill have a first portion of some dimensions and a second portion ofsome dimensions coupled to the first portion at some angle thereto sothat an opening 150 formed through the second portion 114 can be adaptedto align with the corresponding circuit breaker (shown in FIGS. 2, 6).This “height” above a plane on which the sensor module is mounted thatis sufficiently high to allow the CTs to be laterally coupled theretoreduces the bending stresses on the CTs in contrast to bending stresseson the CTs mounted as shown in FIG. 1B. The post 118 can be formedintegrally with the sensor module, such as by molding therewith, orotherwise coupled to the sensor module 62 and in general could be formedwith the second portion 114. Importantly, the post 118 can absorbbending stress 146 caused by the wire 52 bending or otherwise attemptingto misalign the opening 150 with the sensor module 62. Further, theposts transfer bending stresses from wires passing through the posts tothe second portion 114 coupled with the posts, so that the secondportion incurs stress in a shear stress mode that would tend tootherwise tear the second portion material. A shear stress mode can bestructurally accommodated by the thickness of the second portionsufficient to resist tearing from the bending stresses. Thus, theconnections of the CT to the sensor module are generally not undulystressed, absent a catastrophic failure of the coupling portion of thesensor module, such as the posts with the CTs separating from the sensormodule.

A CT 72 can be disposed about the post 118. In at least one embodiment,the CT 72 will be disposed around the post 118, so that the wire 52 isnot in direct contact with the CT 72, that is, the post 118 provides abuffer structure between the CT 72 and any wire disposed through theopening 150. Thus, the CT 78 disposed distally from the wire 52 isgenerally not exposed to undue stress 146 as in prior efforts. If thepost 118 does not have a step, as described in FIG. 3, then the CT willgenerally be disposed in proximity to the second portion 114.

Generally, the CT has a pair of output wires 136 to provide an outputsignal to the monitoring system, shown in FIG. 2. In at least oneembodiment, the output wires 136 can be directly coupled to an outputconnector 80 without intermediate soldering connections other than atthe output connector. Thus, the typical 126 soldering connections for 21CTs found in prior art can be reduced to 42 soldering connections, a 67%decrease in soldering connections. It is believed that this reductionwill result in inherently less failures. To facilitate the output wires136 for each CT traveling to the connector 80, a wire channel 134 can beformed in the sensor module 62. For convenience, the wire channel 134can be formed in the first portion 110. The number of output wires inthe channel will vary depending upon the particular entry of therespective CT to the wire channel. In general, the maximum expectednumber of output wires in the wire channel will be about 42 tocorrespond to two output wires for 21 CTs, in at least one embodiment.Further, the wire channel 134 can be filled with an insulative materialto seal the output wire from the CTs in the wire channel. Thus, thepresent disclosure provides an increased safety margin over prior art bymaintaining the wire 52 carrying the power to the electrical load awayfrom both the CT by way of the post 118 and the output wire 136 from theCT to a separate and in some cases sealed wire channel 134, with anattendant reduction in the number of solder connections and failurerates.

FIG. 5 is a cross sectional schematic view of the sensor module of FIG.3 with a stepped post and a current transformer coupled thereto. FIG. 5is illustrative of the cross section of the sensor module shown in FIG.3 and FIG. 6 passing through a stepped post 120, having a step 122, withthe addition of a CT and relevant wiring. Similar to the descriptionregarding FIG. 4, the sensor module 62 includes the first portion 110,the second portion 114, and a third portion 112, in at least someembodiments. A post 120 is generally coupled to the second portion 114,where the post 120 has an opening formed therethrough that is generallyaligned with a circuit breaker, such as the circuit breakers shown inFIGS. 2, 6. The post 120 can include a step 122. In some embodiments,the step can be formed integrally with the post 120 and in otherembodiments, the step can simply be a cylinder or other geometric shapedcomponent inserted at least partially around, over, attached to, orotherwise coupled with the post 120. In general, the step 122 willrestrict the movement of a CT, such as CT 70, coupled to the post 120 ina direction along the axis of the opening through the post. The offsetdistance caused by the step 122 away from the second portion 114 on thepost 120 can correspond to and allow for close spacing of the post 118,described in FIG. 4, and its respective CT 72 to maintain an axialalignment with circuit breakers at their close spacing. Output wires 132extending from the CT 70 can be routed to and through the wiring channel134 (shown in FIG. 4) that in at least one embodiment can be formed inthe first portion 110. In this embodiment, similar to the embodimentshown in FIG. 4, the post 120 can isolate the CT 70 from the wirepassing through the post 120. The isolation can occur electrically aswell as mechanically, such that a bending stress 146 caused by the wireis generally absorbed by the post 120 and not the CT 70. Thus, the CT 70and its output wires 132 are generally protected and subject to lesssystem failure. The sensor module further includes an output connectorblock 81 with an opening 81A, the block being coupled to the sensormodule 62 to allow an output connector 80, shown in FIG. 2, to beassembled thereto.

FIG. 6 is a perspective schematic view of interfaced sensor modulesbetween a plurality of circuit breakers and respective electrical loads.A first sensor module 62 can interface with a second sensor module 64.The second sensor module 64 can be interchangeable with the first sensormodule 62. Each module can include an output connector 80, 82,respectively. The second sensor module generally will have a similarstructure to the first sensor module so that it includes a first portion110A, a second portion 114A, and a third portion 112A. Generally, thefirst and third portions will be a flange having a wider base thanheight and the second portion 114A will be a web having a larger heightthan width (i.e., thickness of the section). The first, second, andthird portions can be molded as an integral unit in at least someembodiments. Further, the second sensor module will generally have aplurality of posts as has been described above and can be coupled to asupport structure by, for example, coupling the first portion 110A to anelectrical panel, shown in FIG. 2, and in some embodiments facilitatedby a mount 130A.

The first sensor module 62 can include a recessed portion 116 that canbe coupled to a corresponding recessed portion 116A of the second sensormodule 64 in the interface area 66.

One or more circuit breakers 58, 68, 108 can be disposed in theelectrical system 40. Generally, the circuit breakers will be disposedat a fixed relative spacing or an increment thereof The spacing isgenerally determined by the factory-installed rails 138 and the spacingbetween the rails. The rails form a supporting surface for the circuitbreakers to be inserted and generally clipped on or screwed thereto. Forexample, the rail 138 to which the circuit breaker 58 can be coupledthereto, is spaced at a unit spacing 142 from an adjacent rail 140 towhich the circuit breaker 68 is coupled thereto. The electrical systemmay not require a circuit breaker to be coupled to rail 148 and may skipan interval to a rail 152 disposed at a spacing 144, incremental to thespacing 142. Generally and without limitation, the incremental spacingwill occur in integers, such as one spacing, two spacings, and so forth,although fractional increments can be used ,such as one-half andone-third spacings. The circuit breaker 108 coupled to the rail 152 canconnect to a wire passing through the second sensor module for anelectrical load 154. A wire 88 can be disposed between the circuitbreaker 68 and a load 98. Similarly, a wire can be disposed between thecircuit breaker 58 and a load 156. Generally, each wire will passthrough a corresponding CT mounted in either the first sensor module 62or the second sensor module 64. In the interface area 66, the wire couldand generally does pass through both recessed portions of the sensormodules 62, 64. For example, in at least one embodiment, post 124A, 126Aformed in the recessed portion 116A of the second sensor module 64 couldbe aligned with and overlap corresponding posts on the recessed portion116 of the first sensor module 62, as described in reference to FIG. 3.

In at least one exemplary embodiment and without limitation, it isexpected that the sensor modules would include 22 posts with the first21 posts having CTs mounted thereon starting from the output connectoron the end. The 22^(nd) post of each module would overlap with thecorresponding 21^(st) CT of the other module. For example, a CT mountedon the post 126A of the second sensor module 64 would generally alignwith an opening through a post 126 (shown in FIG. 3) of the first sensormodule 62. Likewise, the post 124A with its corresponding opening of thesecond sensor module 64 would align with the post 126 (shown in FIG. 3)and a CT mounted thereon of the first sensor module 62 in an overlappingfashion so that the wires from the circuit breakers to the respectiveloads could pass through both sensor modules in the interface area 66and maintain alignment with the spacing 142 if circuit breakers werepresent in both locations.

While FIGS. 3-6 illustrate a non-limiting embodiment of the sensormodule, the sensor assembly broadly described in FIG. 2 can includecircuit boards and other structures that support the currenttransformers attached thereto.

FIG. 7 is a perspective schematic view of one embodiment of a circuitboard as an exemplary sensor support, having certain aspects taught inthis disclosure. A circuit board 176 can include one or more CTs 74, 78coupled thereto. The CTs can be coupled to the circuit board bysoldering, fastening, forming, or other means. As described above, aplurality of circuit boards can be disposed adjacent each other in anend to end fashion to provide additional capacity for servicing a largernumber of circuit breakers than individual circuit boards.

To solve the above referenced issue of alignment between the closelyspaced circuit breakers 58, 68 and the CTs on the circuit boards at theends of the circuit boards, an interface area 66 can be formed betweenthe adjacent circuit boards 176, 178. The first circuit board 176 caninclude a recessed portion 116 and the second circuit board 178 caninclude a recessed portion 116A, similar to the recessed portionsdescribed above in reference to the sensor modules in FIGS. 3-6. Therecessed portions can be substantially symmetrical between the circuitboards to allow interchangeability when inverting one or more of thecircuit boards. The CTs 74, 78 can be mounted laterally relative totheir respective recessed portions 116, 116A of their circuit boards.When the circuit boards 176, 178 are mounted adjacent each otherend-to-end, the recessed portions 116, 116A can be laterally aligned inthe interface area 66 in a side-by-side fashion and allow the CTs 74, 78to maintain a relative alignment with the circuit breakers 58, 68. TheCTs can be mounted laterally offset from each other on the circuit boardto allow a closer axial spacing 170 between adjacent axes 172, 174passing through the apertures than if mounted without the offset. Suchalignment would otherwise be unavailable as in prior efforts because thedimensions of the CTs have not allowed sufficiently close spacing as thedimensions of the circuit breakers. Wires 78, 108 passing through CTs74, 78, respectively, can be routed from the circuit breakers throughthe CTs 74, 78 in relative alignment and lessen associated bendingstresses that otherwise can cause failures in the system.

Various basics of the invention have been explained herein. The varioustechniques and devices disclosed represent a portion of that which thoseskilled in the art would readily understand from the teachings of thisapplication. Variations are possible and contemplated and are limitedonly by the claims. Details for the implementation thereof can be addedby those with ordinary skill in the art. Such details may be added tothe disclosure in another application based on this provisionalapplication and it is believed that the inclusion of such details doesnot add new subject matter to the application. The accompanying figuresmay contain additional information not specifically discussed in thetext and such information may be described in a later applicationwithout adding new subject matter. Additionally, various combinationsand permutations of all elements or applications can be created andpresented. All can be done to optimize performance in a specificapplication.

The various steps described herein can be combined with other steps, canoccur in a variety of sequences unless otherwise specifically limited,various steps can be interlineated with the stated steps, and the statedsteps can be split into multiple steps. Unless the context requiresotherwise, the word “comprise” or variations such as “comprises” or“comprising”, should be understood to imply the inclusion of at leastthe stated element or step or group of elements or steps or equivalentsthereof, and not the exclusion of any other element or step or group ofelements or steps or equivalents thereof Further, any documents to whichreference is made in the application for this patent as well as allreferences listed in any list of references filed with the applicationare hereby incorporated by reference. However, to the extent statementsmight be considered inconsistent with the patenting of this inventionsuch statements are expressly not to be considered as made by theapplicant(s).

Also, any directions such as “top,” “bottom,” “left,” “right,” “upper,”“lower,” and other directions and orientations are described herein forclarity in reference to the figures and are not to be limiting of theactual device or system or use of the device or system. The device orsystem may be used in a number of directions and orientations.

1. A sensor module for wiring in an electrical system, comprising: a. afirst portion of material with a second portion of material beingdisposed at an angle to the first portion; b. at least one post coupledto the second portion, the post having an opening therethrough orientedat an angle to the second portion; and c. at least one currenttransformer coupled to the post, the current transformer having anaperture aligned with the post opening and the post adapted to insulatethe current transformer from a wire passing through the post opening. 2.The module of claim 1, wherein the first portion and the second portionare integrally formed as a unit in a molding process.
 3. The module ofclaim 1, wherein the first portion comprises a first flange, the secondportion comprises a web having a lesser cross sectional thickness thanthe first flange, and wherein the post is coupled to the web.
 4. Themodule of claim 3, wherein the module is mounted to a structure and thepost is laterally coupled to the web at a height above a plane on whichthe module is mounted to align with a circuit breaker mounted adjacentto the module and allow a wire to pass in alignment from the circuitbreaker through the post opening.
 5. The module of claim 3, furthercomprising a second flange coupled to the web distally from the firstflange.
 6. The module of claim 1, wherein at least one post comprises astep coupled to the post and is adapted to restrict a range of axialmovement of the current transformer coupled to that post along a lengthof the post.
 7. The module of claim 6, further comprising a plurality ofposts without the step arranged along a length of the module inalternating order with a plurality of posts having the step.
 8. Themodule of claim 1, further comprising an output connector and whereinthe current transformers have output wires that are directly coupled tothe output connector.
 9. The module of claim 8, further comprising awiring channel formed in the module for the output wires to be coupledfrom the current transformers to the output connector.
 10. An electricalsystem, comprising: a. an electrical panel; b. at least one circuitbreaker coupled to the electrical panel; and c. the sensor module ofclaim 1 coupled to the electrical panel.
 11. The system of claim 10,further comprising a plurality of circuit breakers coupled to theelectrical panel at an incremental spacing relative to each other and aplurality of current transformers aligned with at least a portion of theplurality of circuit breakers at the incremental spacing to allow wiringto pass in alignment from the circuit breakers through the currenttransformers.
 12. The system of claim 11, further comprising a secondsensor module interchangeable with the first sensor module and adaptedto be mounted end-to-end adjacent the first module.
 13. The system ofclaim 12, wherein the molded portion of each sensor module comprises arecessed portion on at least one end of each module, the recessedportion on the first sensor module being adapted to laterally align withthe recessed portion on the second sensor module and maintain alignmentof an overlapping opening in each sensor module at the incrementalspacing of corresponding circuit breakers.
 14. The system of claim 13,wherein the recessed portion of the first and second sensor modules aredisposed on a same end of the modules and an interface area of thesensor modules is formed by inverting the orientation of one of themodules to laterally align the recessed portions.
 15. The system ofclaim 12, wherein the sensor modules comprise a plurality of openingsfor electrical wires to pass therethrough with at least one openingformed in the first module being adapted to align with an overlappingopening of a second sensor module, the second module beinginterchangeable with the first module, and the overlapping openings ofboth sensor modules aligned with one or more corresponding circuitbreakers.
 16. The system of claim 10, further comprising an electricalload coupled to the circuit breaker.
 17. The system of claim 10, whereinat least one output wire from the current transformer is directlycoupled to an output connector of the module.
 18. The system of claim17, further comprising a wiring channel formed in the module.
 19. Thesystem of claim 17, further comprising a plurality of currenttransformers, each transformer having at least one output wire, whereinthe wires from the transformers are directly coupled to the outputconnector of the module.
 20. The system of claim 10, further comprisingat least one processor to receive input from the current transformer.21. The system of claim 10, further comprising a monitoring systemadapted to determine current flow through the current transformer. 22.The system of claim 21, further comprising a second sensor module havingat least one current transformer coupled thereto, the second sensormodule being interchangeable with the first sensor module and adapted tointerface with the first sensor module by inverting the orientation ofthe second sensor module.
 23. The system of claim 22, wherein themonitoring system is adapted to adjust for reversal in indicatedpolarity from the current transformer on the inverted sensor module. 24.The system of claim 23, wherein the monitoring system is adapted tochange an identity of the current transformer based on the reversal inthe indicated polarity.
 25. The system of claim 22, wherein the firstsensor module comprises 21 current transformers identified astransformers 1-21 and the second sensor module comprises 21 othercurrent transformers identified as transformers 1-21 and wherein thecurrent transformers coupled to the inverted second sensor module arereidentified in the monitoring system as transformers 42-22,respectively, based on a reversal in the indicated polarity of currentthrough the current transformers coupled to the inverted sensor module.26. The system of claim 21, further comprising a first currenttransformer having a wire passing therethrough and a second currenttransformer having the same wire passing therethrough, the secondcurrent transformer being coupled to the monitoring system and themonitoring system adapted to receive input from the second currenttransformer on the same wire independent of the first currenttransformer.
 27. The system of claim 26, wherein the second currenttransformer indicates a reversed polarity relative to other currenttransformers in the system and wherein the monitoring system is adaptedto adjust for the reversal in indicated polarity from the second currenttransformer.
 28. An electrical system, comprising: a. an electricalpanel; b. a plurality of circuit breakers coupled to the electricalpanel at an incremental spacing relative to each other; and c. a firstsensor module, comprising: i. a first flange and a web having a lessercross sectional thickness than the first flange, the web having aplurality of openings formed therethrough at an angle to the web; andii. a plurality of current transformers coupled to the web of the moldedportion, the current transformers aligned with at least a portion of thecircuit breakers at the incremental spacing to allow wiring to passthrough the current transformers in alignment with the circuit breakers.29. The system of claim 28, wherein the first flange and the web areintegrally formed as a unit in a molding process.
 30. The system ofclaim 28, further comprising a second flange coupled to the web distallyfrom the first flange.
 31. The system of claim 28, further comprising aplurality of posts coupled to the web, at least some of the openings inthe web being formed through the posts, and the plurality of currenttransformers being coupled to the posts, the current transformers havingapertures aligned with the post openings, the posts being adapted toisolate the current transformer from a wire passing through the postopening.
 32. The system of claim 31, wherein a portion of the pluralityof posts comprises a step coupled to each post adapted to restrict arange of axial movement of the current transformer coupled to that postand wherein the plurality of posts without the step are arranged along alength of the module in alternating order with the portion of posts withthe step.
 33. The system of claim 28, wherein the sensor module furthercomprises a wiring channel for output wires from the plurality ofcurrent transformers to an output connector coupled to the moldedportion.
 34. The system of claim 28, further comprising a second sensormodule having a plurality of posts coupled thereto and a plurality ofcurrent transformers coupled to the posts, the second sensor moduleadapted to maintain an axial alignment between at least one overlappingopening on each module and wherein the overlapping openings are alignedwith at least one circuit breaker.
 35. The system of claim 34, whereinthe recessed portions of the first and second modules are disposed on asame relative end of the modules and an interface is formed between therecessed portions by inverting the orientation of one of the modules toalign the recessed portions.
 36. The system of claim 28, furthercomprising a monitoring system adapted to determine current flow throughthe current transformers.
 37. The system of claim 36, further comprisinga second sensor module interchangeable with the first sensor module andadapted to interface with the first sensor module by inverting theorientation of the second sensor module.
 38. The system of claim 37,wherein the monitoring system is adapted to adjust for reversal inpolarity from one or more current transformers indicating a reversedpolarity.
 39. The system of claim 38, wherein the monitoring system isadapted to change identities of the current transformers based on thereversal in the indicated polarity.
 40. The system of claim 38, whereinthe first sensor module comprises 21 current transformers identified astransformers 1-21 and the second sensor module comprises 21 othercurrent transformers identified as transformers 1-21 and wherein uponreversal of one of the modules to interface with the other module, theinverted module current transformers are re-identified in the monitoringsystem as transformers 42-22, respectively, based on the reversal in theindicated polarity of current through the inverted module currenttransformers.
 41. The system of claim 28, further comprising a firstcurrent transformer having a wire passing therethrough and a secondcurrent transformer having the same wire passing therethrough, thesecond current transformer being coupled to the monitoring system andthe monitoring system adapted to receive input from the second currenttransformer on the same wire independent of the first currenttransformer.
 42. The system of claim 41, wherein the second currenttransformer indicates a reversed polarity relative to other currenttransformers in the system and wherein the monitoring system is adaptedto adjust for the reversal in indicated polarity from the second currenttransformer.
 43. The system of claim 28, further comprising a firstprocessor to receive input from the current transformers and a secondprocessor remote from the first processor to receive input from thefirst processor.
 44. The system of claim 28, further comprising anelectrical load coupled to the circuit breaker.
 45. A sensor module forwiring in an electrical system, comprising: a. a sensor support having asupporting surface and a second surface at an angle to the supportingsurface and establishing a height above the supporting surface; b. atleast one post laterally coupled to the sensor support along the heightof the second surface, the post having an opening therethrough orientedat an angle to the second surface; and c. at least one currenttransformer coupled to the post, the current transformer having anaperture aligned with the post opening and the post adapted to insulatethe current transformer from a wire passing through the post opening.46. The module of claim 45, wherein the height is of a dimension suchthat a wire from a circuit breaker mounted adjacent the sensor modulecan pass laterally through the sensor module in alignment with thecircuit breaker.
 47. The module of claim 45, comprising a first portionof material to establish the supporting surface and a second portion ofmaterial being disposed at an angle to the first portion to establishthe second surface.
 48. The module of claim 47, wherein the firstportion and the second portion are integrally formed as a unit in amolding process.
 49. The module of claim 47, wherein the first portioncomprises a first flange, the second portion comprises a web having alesser cross sectional thickness than the first flange, and wherein thepost is coupled to the web.
 50. The module of claim 49, wherein themodule is mounted to a structure and the post is laterally coupled tothe web at a height above a plane on which the module is mounted toalign with a circuit breaker mounted adjacent to the module to allow awire to pass in alignment from the circuit breaker through the postopening.
 51. The module of claim 49, further comprising a second flangecoupled to the web distally from the first flange.
 52. The module ofclaim 45, wherein at least one post comprises a step coupled to the postand is adapted to restrict a range of axial movement of the currenttransformer coupled to that post along a length of the post.
 53. Themodule of claim 52, further comprising a plurality of posts without thestep arranged along a length of the module in alternating order with aplurality of posts having the step.
 54. The module of claim 45, furthercomprising an output connector and wherein the current transformers haveoutput wires that are directly coupled to the output connector.
 55. Themodule of claim 54, further comprising a wiring channel formed in themodule for the output wires to be coupled from the current transformersto the output connector.